Method and device for producing formed food products and food product

ABSTRACT

The invention relates to a method for producing formed food products in which a frozen primary product is produced from one or a plurality of foods, in particular from meat, fish, game, poultry, carbohydrates and/or vegetables, or a combination and/or a mixture composed thereof, and the primary product is formed into the food product with a desired contour as part of processing in a processing line by means of at least one forming process, wherein during the forming process at least one pressure stamp presses the primary product against a flat or contoured abutment in order to produce the contour. The known forming methods are to become gentler by means of the invention. 
     For gentle processing the invention proposes clocking the reforming or reforming in a plurality of pressure- or distance-controlled partial pressing steps.

The invention relates to a method for producing formed food products in which a frozen primary product is produced from one or a plurality of foods, which contain in particular meat, fish, game, poultry, carbohydrates and/or vegetables, or a combination and/or a mixture composed thereof, and the primary product is formed into the food product with a desired contour as part of processing in a processing line by means of at least one forming process, wherein during the forming process at least one pressure stamp presses the primary product against a flat or contoured abutment in order to produce the contour.

The invention further relates to a device for implementing this method and a food product which is produced according to this method.

Methods for producing formed food products of this type are known from EP 1 156 720 B1. In this method, whole pieces of grown meat are used as the primary product, which are introduced into a mold cavity and reformed into a geometry which is predefined by the mold cavity by means of a pressure stamp. Depending on the height and width of the primary product, reforming must be carried out to a greater or lesser extent. The piece of meat formed in this manner is then removed from the mold cavity and can then be fed to further processing, in particular to a cooking or other preparation process.

Although meat products with a desired form can be produced with the known method, there is the risk owing to the reforming of the meat that the structure of this meat is changed, despite processing which is as gentle as possible, to such an extent that the piece of meat produced in this manner differs from a natural piece of meat, in particular with respect to its visual appearance, tenderness and bite for the consumer.

Furthermore, the risk always exists with large deformation distances that cracks occur inadvertently in the cell structure of the meat, which can destroy the impression of a cohesive piece of meat, or during the subsequent cooking process can lead to the meat falling apart along this crack, discolorations appearing at these points, other ingredients entering these regions of destroyed cell structure or the product at least seeming fibrous.

The object of the invention is therefore to modify the method given at the start in such a manner that the primary product can be reformed more gently so that on the one hand the applicability of the method can be extended to other types of primary product and on the other hand the primary product is damaged as little as possible by the reforming process.

This object is achieved according to the invention in that the pressure stamp applies the pressure in at least two partial pressing steps, which are separated from each other by an intermediate step or a pause, wherein in a first partial pressing step the primary product is pre-formed and in a second partial pressing step the primary product is further formed by increasing the pressure and/or by further applying the pressure stamp in the direction of the abutment.

The reforming, also referred to in the technical field with the technical term “shaping”, is now carried out in individual steps or in a cyclical manner by the method according to the invention. Two or more partial pressing steps are carried out consecutively, wherein an intermediate step is provided in each case after the partial pressing steps. This intermediate step can consist of just a pause in which the pressure stamp stops in its current position without withdrawing or decreasing.

It is however also possible for the intermediate step to contain either a withdrawal of the stamp as far as loss of contact with the primary product or also for further method steps to be used within the intermediate step. For example it would be possible with a corresponding configuration of the forming device for the pressure stamp, during the intermediate step, rather than being further lowered, to maintain its pressure on the primary product continuously and ensure relaxation of the preformed parts of the primary product by means of a relative movement between the abutment and the primary product or between the pressure stamp and the primary product in massage directions which are arranged at right angles to the pressing direction.

According to the invention all types of foods, including those for animal nutrition, can be used as primary products. The invention is therefore not restricted to the preparation of meat, poultry or fish, including the interior of the said meat or fish products and including any fully or partially precooked or prepared or otherwise already partially processed products, all other foods and recipes of foods, for example vegetables, bread or pasta or similar can be used.

An essential feature of the preferred forming method is the fact that the primary product is first deep-frozen either as a natural product or as a preprocessed product, with in this case a temperature being selected which ensures that, despite any salt content, the primary product is cooled to a temperature below its freezing point or the freezing point of any liquids contained in the primary product. In general the application of the invention should not be restricted to this, in theory an incompletely frozen mixture or a completely thawed primary product can also be processed by the method according to the invention, with it being possible for such primary products to be conceivable even if a further cooking process is carried out directly after the forming process.

An example of the preparation of the primary product before it is subjected to the method according to the invention is the preparation of meat pieces. When processing meat products, the meat is usually prepared before the forming process by means of the known method of tumbling, in which spice marinades are massaged into the meat. The composition of the natural meat is changed by the addition of the spice marinade by means of this massage process, so that in this case a shift will take place in the freezing point from the freezing point of water towards the lower temperatures. Accordingly, the primary product is cooled to a correspondingly lower temperature so that it can be reformed in the frozen state.

In the case of vegetable mixtures, vegetable-filled meat or pasta or the like, the freezing point can be reduced by embedded recipe constituents such as spice sauces, mustard portions or also certain basic products. In this case too a suitable temperature preferably ensures that a frozen primary product is processed.

This frozen primary product has the advantage compared to a non-frozen primary product that it is substantially more stable after reforming as a consequence of embrittlement owing to the freezing process and the adhesive forces of the liquid crystals which arise with the freezing process. In principle, the application of the invention to non-frozen formed products is also conceivable, so the following description of the advantages which are essential to the invention is not intended to be restricted to frozen formed products but rather should be understood to mean that the invention can be implemented particularly advantageously with frozen primary products.

In the simplest case, the invention can just effect a compression of the primary product without using a specific, well-like mold cavity. Such a method is conceivable for example for producing preforms which are to be further processed subsequently as Wiener schnitzel. As these schnitzel are known to have a very thin meat layer, in this case a normal piece of meat can be pressed to the desired thinness.

An alternative configuration of the invention uses in contrast a molding cavity into which the primary product is pressed. In this case a food product can be produced by a selected contour, which product has either a particularly funny shape in order to make it more attractive to children, or has the shape of a natural food despite an originally different shape. It is therefore possible for example to produce a food from meat sections of any shape, the shape of which food corresponds to a steak or a hamburger.

In addition to the processing of meat, the method according to the invention can also be used in the preparation of all other foods. It is thus not only possible for vegetable products to be formed for example, but it is also conceivable for pasta to be produced in this manner or in particular for combinations of the said products to be used as the primary product. The use of frozen primary products can not only be sensible for the reason of better processability of the frozen material, but also the prevention of contamination, for example by salmonella in the case of egg- or poultry-containing products, is substantially improved here.

According to the invention, the method of reforming in the proposed partial pressing steps is then carried out, wherein a simple configuration of the invention consists in that the pressure stamp is lowered in a cyclical manner onto the primary product and thus achieves the desired reforming gradually in a light hammering movement. The duration of the partial pressing steps can in principle be set as desired, partial pressing steps between 0.1 seconds and 60 seconds, in particular between 0.5 seconds and 2 seconds have proved particularly advantageous. The advantageous duration of a partial pressing step ultimately also depends on the required degree of deformation and of course on the material of the inserted primary product.

In one possible process implementation it is possible for the deformation speed to be measured during the forming process, in order to be able to react to unexpected states, in particular a high degree of deformation. If for example meat with a wide variety of geometries but the same weight is introduced into the forming device, the degree of deformation which is necessary to produce uniform products can vary very greatly depending on the basic shape. In this case it can be sensible in the event of high degrees of deformation to interrupt the affected partial pressing step, which would be the partial pressing step which is applied for longer per se, early in order to allow the highly deformed meat a period of rest for internal relaxation or to relax this meat by means of the said massage steps.

A preferred configuration of the method according to the invention uses not only two but a multiplicity of partial pressing steps, for example 10, 20 or 30 partial pressing steps. These partial pressing steps can have a uniform or different duration. It has proved advantageous in particular in conjunction with the deformation of meat for example in an application that more than 5, for example approximately 10-15 partial pressing steps are used, which have in each case a length of approximately one second. In each case a pause which can likewise be one second is provided in between. In this manner an effect is produced which corresponds approximately to a continuous, light hammering, with the pressure stamp moving slightly further towards the abutment with each partial pressing step.

It can be sensible to configure the length and the pressure to be applied of the partial pressing steps differently for each material of the primary product and the required or expected degree of deformation. For example, it can be advisable to shorten the partial pressing steps with increasing deformation, which can be recommended in particular in primary products which have a compression to be equalised which is small in the transverse direction but great in the pressure direction. In this case the first coarse deformation can be carried out with a correspondingly large travel distance of the pressure stamp, whereas the later, final forming occurs with smaller distances, but with correspondingly greater quantities of meat to be deformed owing to the larger contact area. In the later stage it can then be sensible to reduce the deformation distances for example by shortening the duration of the partial pressing steps.

Depending on the shape of the primary product, however, the opposite approach can also lead to the large travel distances taking place in smaller stages whereas the smaller travel distances can be carried out with whole-area contact in one step. This can for example be advisable if the primary product consists of a mixture of very different foods and a mixture or product projects upwards in the center which is to be pressed in its width slowly downwards by the forming process in such a manner that it is pressed for example into the lower mass, a pasta product for example, but does not fall apart beforehand.

Alternatively or additionally to this, a reduced reforming pressure can of course be used instead of a reduced reforming distance at later or earlier times. In order to process the primary product gently, the reforming pressure can be applied to pressure stamp in a wide variety of ways during the individual partial pressing steps. In the simplest case a “spontaneously forming pressing step” is used, in which the pressure desired for the respective partial pressing step is transmitted spontaneously, that is, without any intentional delay and fully to the pressure stamp. If this pressure then leads to a certain deformation of the primary product, the pressure can be reduced by this deformation, as the pressure system also partly relaxes during a merely brief introduction of the working pressure into the working piston of the pressure stamp by the movement of the pressure stamp and the associated enlargement of the working piston. The working pressure can however also be maintained unchanged so that a correspondingly faster further deformation can take place.

Alternatively a purely distance-controlled spontaneous deformation can take place, wherein during this partial pressing step the deformation can be carried out along a predefined, in particular straight course of the pressure stamp, irrespective of the reaction of the primary product. The wide variety of partial pressing steps can be combined with each other in any desired manner according to requirements or experience with the processing.

Different intermediate phases can be provided between the partial pressing steps. In most cases it will be sufficient to allow the partially reformed primary product a pause during which the structures of the primary product can recover from the reforming pressure or also broken frost connections can be closed up again by renewed freezing together. The latter is recommended in particular when reforming loose mixtures such as pasta or rice products which are only bound together by the frost connection of the individual constituents. In this case a new bond can be produced by adding water vapor or similar measures.

In other cases it can in contrast be sensible to increase the recovery of the primary product by subjecting the primary product to a massage. The pressure stamp can thus for example execute rotary or translatory movements in the plane at right angles to the pressing direction. In this case it should of course be held in contact with the surface of the partially reformed primary product so that a slight rolling or kneading load of the meat is produced, with phases of lateral displacement or relaxation. This can be reinforced by a tumbling movement of the pressure stamp which can also be exchanged for the pressure stamp of the partial pressing step. Ultrasound excitement of the pressure stamp is also possible to calm the primary product.

Finally, a kinematic reversal of the above-mentioned measures can of course also take place, so that the abutment then executes the corresponding movements and the pressure stamp remains still. A combination of moved pressure stamp and moved abutment is of course also possible to have an effect on both sides of the primary product.

During the still phases, the pressure stamp can also be withdrawn by a defined distance. Defined distance means in this case moving back by a certain distance, but also means that the pressure stamp may yield by a certain counterpressure, that is, readjust itself depending on the pressure. The latter is in particular sensible if, as described above, a massage function of the primary product is to be implemented by a movement of the pressure stamp.

An undesirable restoration of the partial deformation by a memory effect can also be restricted or prevented in this manner, as with the pressure-dependent restoration a certain forming effect of the pressure stamp is retained even during the rest phase. In this manner a further deformation can take place, for example by flowing of the material under stress, even during the rest phase and the reduction of the stresses inside the individual layers of the primary product.

In principle, the withdrawal of the pressure stamp or the yielding of the pressure is conceivable in any possible manner and can in a simple case take place by simply withdrawing the pressure stamp by a certain distance. Alternatively, the application pressure can also simply be reduced partially or to ambient pressure. It is furthermore also possible to carry out the withdrawal of the pressure stamp more slowly along a straight, progressive or also degressive distance and/or pressure profile.

A further configuration of the method according to the invention has partial pressing steps which are composed of a distance-controlled forming phase and a pressure-controlled forming phase. During the distance-controlled forming phase, the pressure stamp is applied against the abutment by a predefined distance irrespective of the pressure conditions. During the pressure-controlled phase, in contrast, a reaction can be made to the counterpressure of the primary product so that in this case a certain maximum pressure which is defined depending on the load-bearing capacity of the primary product is not exceeded. This method has the advantage in particular that damage to the primary product can be avoided even more effectively.

A possible application of these two-phase partial pressing steps consists for example in that initially a first distance, which is not critical with respect to damage to the structures, is traveled through in a distance-controlled manner, whereas the second distance, which is more critical with respect to damage can then be traveled in a pressure-controlled manner. Other applications take account of the unloading of the for example meat-like primary product during the pressure-controlled forming phase, so that despite the increasing pressure a maximum deformation result with an undamaged structure can be achieved by the alternation over time of distance-controlled and pressure-controlled forming phases within one partial pressing step.

In principle, all combinations of consecutively arranged, distance- or pressure-controlled phases are possible within a single partial pressing step, even repeated multiply. It is finally also possible for partial pressing steps to be configured as continuously forming partial pressing steps, wherein in this case the pressing step is carried out along a load curve which is predefined previously, irrespective of the reaction of the primary product which is under pressure. The reforming can be terminated when a maximum pressure or a maximum reforming distance is reached.

The predefined load curve can be linear, progressive or degressive. Furthermore, a phase of the unloading during which the pressure is slightly reduced again or also a continuous loading phase during which the pressure is kept constant, can follow. The second phase can also be characterised by a stationary pressure stamp so that in this case a phase with a constant stamp position is provided after the first, pressure-increasing phase is complete, irrespective of the forming pressure.

The method according to the invention is therefore composed of any desired combinations of partial pressing steps of this kind, simple partial pressing steps without changing between pressure and distance control and a wide variety of pause steps with or without effect on the material.

A further configuration of the method according to the invention relates to the particular configuration of the pressure stamp or of the abutment. Depending on the primary product, it can be possible for very high loads and very large reforming distances to occur locally, whereas other regions of the molding cavity or of the primary product are loaded or reformed to a lesser extent or not at all. It often becomes very difficult to take account of all condition beforehand, as for example different shapes of primary products are often to be formed. For example, during a meat production process a thin, flat primary product can be present for processing just as much as a cube-shaped or a vertical, narrow, tall piece of meat.

It is obvious that the loads on the pressure stamp, the abutment and of course the primary product are completely different in the above-mentioned cases. A pressure stamp which is elastic can take account of these conditions, so that the pressure stamp can initially avoid peak loads in that the stamp surface deforms in a load-dependent manner. This is reversed during the course of the further stroke by the elastic restoring forces so that the desired homogeneous deformation of the primary product can take place.

In a further particular configuration of the pressure stamp, it is also possible for it to be elastic during one or a plurality of partial steps while being stiffened during subsequent partial steps so that it has a flat pressure surface which does not migrate. To this end, the pressure stamp can for example have a lower pressure plate which is connected via the actual stamp body by means of springs. These springs effect an elasticity of the pressure stamp during the first partial steps so that the regions of greater loading are subject to lower deformation. If this pressure stamp has reinforcing bolts which can be moved mechanically, hydraulically or pneumatically from the pressure stamp towards the lower pressure plate, the spring effect can be interrupted so that the pressure stamp then has a flat, no longer resilient pressure plate. These bolts can also be moved even before the start of one of the partial pressing steps so that the pressure stamp exhibits uniform behaviour in terms of spring technology during this partial pressing step but behaviour including the springs during another partial pressing step.

Alternatively, these bolts can however also be used while carrying out the partial pressing step so that for example in addition to the actual pressure in the regions in which the pressure plate has migrated, the migration can be reversed by the pressure of the bolts so that in this case an additional pressing force can be exerted on the regions of increased counterpressure with the distance or pressure if the actual pressure stamp is kept constant. This counterpressure can also be built up spontaneously or in a pressure- or distance-dependent manner.

If migration of the pressing surfaces is made possible or prevented as described above by means of a resilient contact force between the pressure stamp, the abutment and the primary product which is arranged between these two structural parts, this can of course also take place on the part of the abutment. This is particularly preferable if a workpiece carrier with one or a plurality of mold cavities is used as the abutment. In this case the mold cavity can be arranged resiliently on the workpiece carrier. A resiliently mounted mold cavity of this type can either be pressed down by the pressure stamp as far as the stop of the spring so that the spring effect is interrupted, but alternatively a special device can be provided which interrupts the spring effect.

The latter can consist in that the pressure stamp has an outer region which can be actuated and moved separately relative to the inner region and presses the edges outside the mold cavity against a frame so that the mold cavity is fixed on the supporting edge. The inner pressure stamp which fills out the mold cavity can then be moved into the mold cavity in order to deform the primary product. Alternatively, the workpiece carrier itself can also have the above-described bolts which can be moved from the workpiece carrier towards the frame of the mold cavity so that the latter is fixed in the pressing direction.

A further configuration of the invention can use a mold cavity which is held by means of hydraulic or pneumatic bearings which can be actuated selectively in such a manner that they can apply a pressure force counter to the pressing force. A three-point or four-point bearing can for example be provided which holds a frame on which the mold cavity is in turn fastened. A hydraulic or pneumatic actuation member which can press the mold cavity against the stamp can be provided at each of the bearing points. If peak loads then occur in the region of the mold cavity, the resiliently mounted mold cavity would tilt. In order to avoid precisely this, or even to be able to produce a tilt in the opposite direction, the mold cavity can then be aligned by means of the hydraulic or pneumatic bearings in such a manner that the pressures in the region with the greater accumulation of material are increased and thus parts of the primary product are pressed in order to achieve a more homogeneous distribution of material in the region of lower pressures.

During the partial pressing steps, the primary product can be exposed to different loads by a pressure stamp which is moved constantly or in an accelerated or delayed manner. The entire movement of the pressure stamp, in particular during the phase of the acceleration or of the delay, can take place in a predefined or also pressure-dependent manner. Which combination is most advantageous for the primary product is produced in each case from the consistency of the primary product and is preferably determined by means of experiments.

The behaviour of the primary product and its loading can be determined during the method by means of pressure measurement. The pressure loading can be determined using the loading of the central pressure stamp, but pressure sensors are also possible which determine the loading point by point over the entire pressure surface or in a planar manner. The latter can for example take place by using a piezoelectric sensor film by means of which the entire region of the pressure surface can be monitored. If a critical pressure is then established, either the pressure can be reduced, the exposure time of the pressure can be reduced or else the movement speed of the pressure stamp can be reduced, while maintaining the other process variables in each case. Below the critical pressure, deformation can take place either at constant pressure force or at constant movement speed.

A preferred processing device for foods has at least one of the described forming devices. An abutment can be arranged inside this forming device if a specific contour is to be achieved, this can be a mold cavity. However a plurality of mold cavities are preferably provided per forming device so that a plurality of food products can be produced with one forming process of the forming device. A placement device can fill the multiplicity of mold cavities with primary products before applying the process pressure, alternatively a workpiece carrier can also be used which has the mold cavities and is inserted into the forming device already filled. The latter is interesting in particular when using an entire processing line.

Such a processing line can then also have a preprocessing stage if for example the primary products are first combined to form a block of food products which is then divided portion by portion into the individual primary products by means of a cutting device, in particular a band saw. This block can for example consist of frozen meat, with it being possible for the meat pieces to be tumbled or otherwise prepared in a non-frozen state and then combined to form a block which is then frozen.

After the primary products which have been prepared in this manner are inserted into the mold cavities or placed onto the abutment, the deformation can take place by means of the forming device according to the above-described method options. In the simplest case, a single forming device is used for this.

In an advantageous development of the invention, the pressure stamp can also be contoured, that is, have a non-flat surface. Products which are supposed to be contoured on their surface can be produced hereby in one application.

Alternatively, a contoured pressure stamp which can have for example an eccentric projection which springs towards the primary product or a plurality of ball-shaped regions can also be used for preparatory shaping inside the reforming device. In order that the lowest points of the pressure stamp can act on all regions of the primary product, the pressure stamp can be turned during the partial pressing steps, preferably by an angle which is produced from the total number of the partial pressing steps such that after all the partial pressing steps are complete the pressure stamp is turned by 360°. With 6 partial pressing steps provided, a rotation of in each case 60° would therefore take place so that virtually every region of the primary product has come into contact with every region of the pressure stamp.

The above-described rotatable pressure stamp can be exchanged for the final forming stamp by a manual or automatic tool-changing process, or it is used in a first forming device, wherein the mold cavity together with the primary product pretreated therein is fed after the pretreatment and the associated preforming to a second forming device which then carries out the final reforming with the final forming stamp. In this two-stage deformation, a wide variety of primary products, in particular very flat primary products on the one hand and very tall primary products on the other hand, can be formed to the same contour in particular by the distance- and/or pressure-controlled application of the pressure stamp, without the meat structure of the structure of the other food being excessively affected by excessively fast reforming speeds.

If a plurality of forming stations are used, a maximum loading can be initially reduced by means of the size of the pressure stamp. The pressure stamp can for example be so small in the first forming station that it only covers part of the mold cavity. This allows the primary product to partially evade the pressure stamp in this early deformation stage. This evasion in turn prevents excessive degrees of deformation. If the pressure stamp is not mounted in a rotatable manner here and is not arranged concentrically to the axis of rotation, the pressure can be exerted on different regions of the abutment or mold cavity by means of a plurality of partial pressing steps. In order to achieve the desired uniform contour in this configuration, the mold cavity or the abutment can then be fed to a second forming station, where a larger pressure stamp which covers the entire mold cavity or the entire area of the primary product can then carry out the final deformation with one or a plurality of partial pressing steps.

The relaxation phases provided between the partial pressing steps can be exactly as long as the partial pressing steps, but it is also possible if required to increase or decrease the length of the relaxation phases. During the relaxation the primary product can be left completely without pressure, alternatively a certain partial pressure can also be maintained. The already described massage of the partially deformed primary product can take place during the partial pressing steps and/or during the relaxation phases by vibrations or short-wave, including those in the ultrasound range, up and down movements of the pressure stamp or of the abutment.

Finally it is possible to take into account the degrees of deformation and the pressure profile during the preceding deformation during the partial pressing step in that either the relaxation phase or at least one of the partial pressing steps is lengthened in the event of very unfavorable pressures or degrees of deformation. To this end, pressure sensors can determine whether the pressure stamp is exposed to a counterpressure over a longer distance range during the travel of the pressure stamp. This produces the fact that obviously the primary product must have been reformed to a considerable extent in the pressure direction. Such a severe reforming then results in a longer relaxation phase.

If on the other hand the pressure stamp has been moved over the same travel without counterpressure, it can be concluded from this that the primary product must have been correspondingly flat so that no great reformation can have taken place despite the long travel. This then results in turn in the optimisation of the process duration in a shorter relaxation phase.

During deformation the primary product preferably has a low temperature. Forming is usually currently carried out at a temperature of minus 15°. In order to improve the flowability of the material, this temperature can be raised to just below the freezing point. As most primary products contain salt-containing substance, in this case the temperature is for example minus 5°. If no salt-containing substances are present, higher temperature can of course be selected, for example just below the freezing point of water (=0° Celsius). The higher temperatures result in it being possible for the deformation to take place more gently. The cell structures can also be prevented from being destroyed in this manner.

The method according to the invention can be used to form a primary product to a desired, predefined height. This will always be the case if for example hamburgers or pieces of meat whose shape corresponds to a schnitzel or a rump steak are to be produced. With this deformation the pressure must be exerted until the desired height is reached. So that this is possible, it must of course be ensured that not too much meat is introduced into the mold cavity if this has an outer border.

If on the other hand no defined height is to be reached, the achievement of a maximum pressure can signal the end of the forming process. In this case the meat is reformed with a maximum permissible pressure, with the height of the finished product being of secondary importance. This is in particular advantageous if the height of the food product essentially does not matter and the height differences are not all that great owing to the supplied primary products and in spite of the purely pressure-controlled process, so that nevertheless essentially uniform products for the food industry can be produced.

Furthermore, the invention relates to all methods which contain a deformation of in particular deep-frozen primary products, irrespective of whether these methods are restricted exclusively to pure deformation or whether there are processing steps upstream or downstream. In particular, products which are combined in any desired manner, partially or fully precooked or finally cooked can be included in the method. The deformed food products can be ready for consumption, require further processing and preparation, or be subjected to food treatment or modification in another manner afterwards.

The invention is however not just restricted to the above-described method. It also includes in particular the device which can be used to carry out the method and the end or intermediate product which can be produced with the device using this method.

The device necessary for carrying out the method is in the simplest case provided with just one forming device, which can apply the pressure force to the primary product in a cyclical manner or with the individual partial pressing steps which are separated from each other by relaxation phases. Optionally, this forming device can be provided with a pressure control system which can vary the applied process pressure either according to a predefined pressure profile curve or which has a sensor system so that the counterpressure which is transmitted from the primary product to the pressure stamp can be determined on the basis of the pressure. Alternatively, the pressure on the abutment can of course also be detected. A visual recording of the reforming result, also from a plurality of viewing directions, can be used as a regulating variable.

Depending on the counterpressure or the degree of reforming, the process pressure can then be selectively increased or reduced for the pressure stamp so that the method steps as described above can be carried out.

A further configuration of the processing line has a second forming device and a feed device by means of which the forming device or devices can be supplied with the primary products. To this end, the primary product can be produced by dividing into individual portions from a larger composite, for example the above-described deep-frozen blocks. These portions can then be distributed automatically onto the abutment or placed into the mold cavities by means of the feed device.

If a forming device can operate a plurality of mold cavities, this can take place by means of a common stamp which is configured on its underside in such a manner that it can penetrate into each mold cavity with individual pressure plates. A plurality of pressure stamps can however also be provided so that each stamp makes possible the above-described method steps, in particular the pressure reactions, by itself. The latter is of course particularly preferable if different geometries of the primary product can be arranged in each mold cavity. If in contrast the primary product is sawn from blocks, each primary product will have approximately the same contour, so that a different reaction to the individual primary products can be superfluous.

The forming device preferably has a pressure stamp which can be applied against the primary product by means of the known methods. A pressing cylinder can in particular be used here, which can be operated by means of servo technology. Of course, hydraulic or mechanical pressing devices can also be used, in the latter case the distance-controlled lowering of the pressure stamp can take place by means of eccentric discs in a similar manner to a camshaft, with a resilient bearing, which can be manipulated by means of pneumatic or hydraulic means, allowing the pressure-regulated functioning of the pressure stamp even in the case of the mechanical drive.

The formed foods produced by the method according to the invention are then removed from the abutment or from the mold cavity. They can then be further processed, they can in particular be subjected to a cooking process or another preparation process. A subsequent deep-freezing process for intermediate storage or for direct sale to the end consumer is of course also possible.

Further features and advantages of the invention can be found in the subclaims. 

1-42. (canceled)
 43. A method for producing formed food products in which a frozen primary product is produced from a food, the method comprising: providing a frozen primary product which comprises a food; performing a first pressing of said frozen primary product against an abutment to produce a pre-formed initial food product; immediately after said first pressing is completed, performing an intermediate process for a predetermined amount of time to produce an intermediate product; and immediately after said predetermined amount of time has elapsed, performing a second pressing of said intermediate food product against said abutment until a final food product with a desired contour is achieved.
 44. The method according to claim 43, wherein said food is selected from the group consisting of meat, fish, game, poultry, carbohydrates and vegetables.
 45. The method according to claim 43, wherein said second pressing comprises pressing said intermediate food product with a force that is greater than a force used during said first pressing of said frozen primary product.
 46. The method according to claim 43, wherein said abutment is contoured.
 47. The method according to claim 43, wherein a duration of said first pressing and said second pressing is between 0.1 s and 60 s.
 48. The method according to claim 47, wherein said duration is between 0.5 s and 2 s.
 49. The method according to claim 43, further comprising measuring a degree of deformation of said frozen primary product during said first pressing, wherein a duration of said first pressing is controlled based on said measuring.
 50. The method according to claim 43, wherein said first pressing, said intermediate process and said second pressing are repeated so that a total number of first and second pressings has a value of between 5 and
 30. 51. The method according to claim 50, wherein durations of said first pressing and said second pressing are shortened with an increasing number of said pressing being performed.
 52. The method according to claim 43, wherein at least one of said first pressing and said second pressing is configured as a spontaneously forming pressing process, wherein during said spontaneously forming pressing process either 1) a pressure force is spontaneously increased to a maximum partial pressure or 2) a deformation distance is increased to a maximum partial deformation and said maximum partial pressure or said maximum partial deformation distance is maintained during a remaining duration of said respective first pressing or second pressing processes.
 53. The method according to claim 43, wherein said intermediate process comprises reducing a pressure force applied to said intermediate food product entirely through or partially through a duration of said intermediate process.
 54. The method according to claim 53, wherein said pressure force is reduced partially through said duration of said intermediate process and said pressure force is increased in said intermediate process at least once until a starting pressure performed in said first pressing is achieved.
 55. The method according to claim 54, wherein during said intermediate process a pressure stamp that performed said first pressing is withdrawn from said pre-formed initial food product by a predefined distance in a pressure-dependent or pressure-independent manner.
 56. The method according to claim 55, wherein said predefined distance is determined in a pressure-controlled manner, wherein said pressure stamp is withdrawn in particular along a predefined, straight, progressive or degressive pressure profile curve until a predefined setpoint pressure is no longer exceeded.
 57. The method according to claim 43, wherein at least one of said first pressing and said second pressing process comprises: a distance-controlled forming phase; and a pressure-controlled forming phase which is carried out before or after said distance-controlled forming phase, wherein during said distance-controlled forming phase and said pressure-controlled forming phase said pressure stamp is applied against either said frozen primary product or said intermediate food product at a speed which is continuous or can be varied over time, but is defined beforehand.
 58. The method according to claim 43, wherein at least one of said first pressing and said second pressing process is configured as a continuously forming pressing process, wherein during said continuously forming pressing process either 1) a pressure force is applied to either said frozen primary product or said intermediate food product or 2) a deformation distance of either said frozen primary product or said intermediate food product is increased continuously until a maximum partial pressure is reached.
 59. The method according to claim 58, wherein said continuously forming pressing process comprises a first phase of increasing pressure until said maximum partial pressure is reached and a subsequent second phase during which said maximum partial pressure is kept constant.
 60. The method according to claim 58, wherein said continuously forming pressing process comprises a first phase with a predefined distance of a pressure stamp that generates said continuously forming pressing and a subsequent second phase with said pressure stamp being held stationary in a pressing direction.
 61. The method according to claim 43, wherein said abutment is elastic at least in a transverse direction with respect to a direction of application of a force during said first and second pressings in such a manner that said abutment can react to locally increased loads by migration of a pressure surface of said abutment.
 62. The method according to claim 43, wherein said first pressing and said second pressing is performed by a pressure stamp that has an elastic contact surface at least in a transverse direction with respect to a direction of application of a force during said first and second pressings in such a manner that said pressure stamp can react to locally increased loads by migration of a pressure surface of said pressure stamp.
 63. The method according to claim 43, wherein a pressure stamp is used to perform said first pressing and said second pressing, said pressure stamp comprises a plurality of individual adjacently arranged pressure elements which form a total pressure surface of said pressure stamp and can be actuated individually, a reaction force of each pressure element can be measured by a sensor system, wherein at the start of each of said first pressing and said second processing processes all said pressure elements are applied uniformly to either said frozen primary product or said intermediate frozen product, and when abutment pressures arise owing to contact of said pressure stamp against an affected part of said frozen primary product or said intermediate frozen product, a pressure force for said pressure stamp is increased at least temporarily to produce a preforming of raised regions of said frozen primary product or said intermediate frozen product.
 64. The method according to claim 43, wherein a pressure stamp is used which has a pressure surface and an effective surface which comes into contact with either said frozen primary product or said intermediate frozen product, wherein said pressure surface and an effective surface are connected to each other by at least one spring in such a manner that said effective surface can spring back in a pressure direction so that when said pressure stamp is applied to either said frozen primary product or said frozen intermediate product, said effective surface is initially restored counter to a spring force and only exerts a full pressure force on either said frozen primary product or said frozen intermediate product when said spring comes to a stop.
 65. The method according to claim 43, wherein said abutment is elastic in a pressure direction and is in particular formed by an elastic pad.
 66. The method according to claim 43, wherein during at least a portion of either said first pressing or said second pressing processes a pressure force applied by a pressure stamp to either said frozen primary product or said frozen intermediate product is kept constant and a degree of deformation is achieved over an application distance of said pressure stamp and an exposure time of said pressure force.
 67. The method according to claim 43, wherein during at least a portion of either said first pressing or said second pressing processes a pressure force applied by a pressure stamp to either said frozen primary product or said frozen intermediate product with a constant pressure force, wherein a degree of deformation is achieved over a duration of movement of said pressure stamp.
 68. The method according to claim 67, wherein said abutment is arranged resiliently in a pressure direction on a pad.
 69. The method according to claim 43, wherein said abutment is elastic in a pressure direction and is in particular formed by an elastic pad.
 70. The method according to claim 43, wherein said abutment is configured in such a manner that it executes small oscillations in at least one direction which runs at right angles to a pressure direction and so either said frozen primary product or said frozen intermediate product is pressed with a slight massaging movement.
 71. The method according to claim 70, wherein said oscillations are ultrasound oscillations.
 72. The method according to claim 43, wherein a pressure stamp is used to perform said first pressing and said second pressing, said pressure stamp is configured in such a manner that it executes small oscillations in at least one direction which runs at right angles to a pressure direction and so either said frozen primary product or said frozen intermediate product is pressed with a slight massaging movement.
 73. The method according to claim 72, wherein said oscillations are ultrasound oscillations.
 74. The method according to claim 43, wherein said abutment is a workpiece carrier with at least one mold cavity into which either said frozen primary product or said frozen intermediate product can be pressed by a pressure stamp, wherein said pressure stamp is adapted in terms of its shape to an inner cross-sectional area of said mold cavity and can be introduced into said mold cavity while closing said mold cavity off laterally.
 75. The method according to claim 43, wherein a pressure stamp is used to perform said first pressing and said second pressing, said pressure stamp comprises a pressure surface which is not parallel to said abutment and is rotated by an angle between said first pressing and said second pressing processes.
 76. The method according to claim 75, wherein said angle is defined by the division of 360° by the number of first and second pressing processes used per frozen primary product.
 77. The method according to claim 43, wherein said first pressing is performed in a first forming station by a first pressure stamp and wherein said second pressing is performed in a second forming station by a second pressing stamp, wherein said second forming station is separate from said first forming station.
 78. The method according to claim 77, wherein said frozen primary product lies within a workpiece carrier during said first pressing performed in said first forming station and wherein said frozen intermediate product lies within said workpiece carrier during said second pressing.
 79. The method according to claim 78, wherein said workpiece carrier comprising a mold cavity for accommodating said frozen primary product and said frozen intermediate product and said first pressure stamp is smaller than a cross-sectional area of said mold cavity, and a pressure surface of said second pressure stamp corresponds essentially to said cross-sectional area of said mold cavity, allowing a clearance between said mold cavity and said first pressure stamp.
 80. The method according to claim 43, wherein said intermediate process comprises a relaxation phase during which a pressure generated on said pre-formed initial food product by a pressure stamp is not increased any further or is reduced.
 81. The method according to claim 80, wherein during said relaxation phase said pressure stamp exerts a constant or reduced pressure and said pre-formed initial food product is massages by a tumbling and/or rotary movement of said pressure stamp and/or of said abutment about an axis which is parallel to a pressure direction.
 82. The method according to claim 80, wherein during said relaxation phase said pressure is reduced to ambient pressure.
 83. The method according to claim 80, wherein a duration of said relaxation phase is between 0.1 s and 60 s.
 84. The method according to claim 80, wherein a duration of said relaxation phase increases with an increasing number of said first and second pressing processes.
 85. The method according to claim 83, wherein a deformation speed or degree of deformation of said frozen primary product is measured, and in the event of a high deformation speed or degree of deformation said duration of said relaxation phase is extended.
 86. The method according to claim 43, wherein said frozen primary product has a temperature between minus 1° C. and minus 30° C. while said method is being carried out.
 87. The method according to claim 43, wherein said first pressing and said second pressing are pressure- or travel-controlled and are applied for so long or so intensively until said food product is compressed to a predefined height.
 88. The method according to claim 43, wherein said first pressing and said second pressing are pressure-controlled and are applied until said food product is exposed to a predefined maximum pressure.
 89. The method according to claim 43, wherein said frozen primary product is a meat product selected from the group consisting of meat, fish, game and poultry, wherein said frozen primary product is produced by gentle tumbling of whole, grown pieces of meat.
 90. The method according to claim 89, wherein said tumbled meat pieces are combined to form a deep-frozen block, wherein said block is then divided into said frozen primary product as a portion of said block with a desired weight by a dividing device.
 91. The method according to claim 90, wherein said dividing device comprises a band saw with parallel saw blades which are arranged at right angles to each other.
 92. A food product generated by the method comprising: providing a frozen primary product which comprises a food; performing a first pressing of said frozen primary product against an abutment to produce a pre-formed initial food product; immediately after said first pressing is completed, performing an intermediate process for a predetermined amount of time; and immediately after said predetermined amount of time has elapsed, performing a second pressing of said intermediate food product against said abutment until a final food product with a desired contour is achieved.
 93. A forming device which can be filled with primary products and is used for producing formed food products from said primary products, the forming device comprising: a pressure stamp; and an abutment which interacts with said pressure stamp, wherein said forming device can change said primary product into a predefined shape or thickness by pressing said primary product between said pressure stamp and said abutment; and wherein said forming device is configured in such a manner that it can apply said pressure stamp against said abutment in a time-, pressure- and/or distance-defined manner in order to carry out the following method: performing a first pressing of a frozen primary product against an abutment via said pressure stamp to produce a pre-formed initial food product; immediately after said first pressing is completed, performing an intermediate process for a predetermined amount of time; and immediately after said predetermined amount of time has elapsed, performing a second pressing of said intermediate food product against said abutment via said pressure stamp until a final food product with a desired contour is achieved.
 94. A forming system for producing formed food products from primary products, the forming system comprising: a device for combining food to form a deep-frozen block; a dividing device for dividing said block into a frozen primary product, wherein said dividing device comprising a band saw with parallel saw blades which are arranged at right angles to each other; a processing line; a transporting device for transporting said frozen primary product through said processing line and a primary product feed device which can feed said frozen primary product to a forming device, wherein said forming device comprises: a pressure stamp; and an abutment which interacts with said pressure stamp, wherein said forming device can change said primary product into a predefined shape or thickness by pressing said primary product between said pressure stamp and said abutment; and wherein said forming device is configured in such a manner that it can apply said pressure stamp against said abutment in a time-, pressure- and/or distance-defined manner in order to carry out the following method: performing a first pressing of a frozen primary product against an abutment via said pressure stamp to produce a pre-formed initial food product; immediately after said first pressing is completed, performing an intermediate process for a predetermined amount of time; and immediately after said predetermined amount of time has elapsed, performing a second pressing of said intermediate food product against said abutment via said pressure stamp until a final food product with a desired contour is achieved. 